Floor construction



Dec. 7, 1937. FABER I 2,101,538

FLOOR CONSTRUCTION Filed March 14, 1936 2 Sheets-Sheet 1 1. INVENTOR 1f Herber-i Faber HlS A EY -.Dec. 7, 19.37.

H. A. FABER FLOOR CONSTRUCTION Filed March 14, 193's 2 Sheets-Sheet -2 l 111. 5. l5a 5 Ila I. '1 I i Herberf A. Faber Ex -med Dec. 7, 1931 UNITED STATES PATENT OFFICE 1'! Claims.

This invention relates to an improved floor construction, and more particularly to a floor construction assembled from pre-shaped blocks of novel configuration tied to one another by suitable reinforcing means.

Embodiments of the present invention include individual blocks pre-shaped, preferably from concrete, to provide sets of parallel depending flanges suitably spaced apart from one another to aiiord, when the blocks and the therewith associated-flanges are positioned in end to end alignment in the floorassembly, a continuous channel suitable for the reception of reinforcing means, the reinforcing means being of a length suflicient to tie the associated units together and to coincidentally tie together associated flanges to complete the formation of composite beams running continuously across the undersurface of the assembled floor.

20 Advantageously. such reinforcing means take the form of rods pre-bent to approximate a catenary, and are positioned with the vertex of the curve directed downwardly, the free ends of i the rod being secured by appropriate means at 25 the edges of the floor proper. Spacer means, having collectively the required coordinating curvature, are provided between the curve of the reinforcing rods and the undersurface of the floor, and permit the stressing of the rods to a 30 degree necessary to enhance the usual load bearing characteristics of the floor construction. It

is desirable that the reinforcing rods be surrounded by a grouting material when in final position.

35 Side surfaces of individual blocks preferably define grooves extending continuously around the lateral periphery of the block to permit a novel joinder, proximate the floor surface, of assembled blocks, the joinder being accomplished by the positioning of inserts at spaced intervals between co-ordinating grooves of respective contiguous blocks, and grouting therebetween.

The uniformity of configuration thus attained between individual blocks permits interchangeability of blocks in various locations in the floor arrangement.

The present invention, therefore, provides a solid floor construction capable of supporting 5') comparatively greatloads, the tying in of individual blocks to form both a flooring surface and beams therefor and the pre-stressing of the tying means, effecting this desired result. 7.

The ease of assembly of the herein floor coni struction and the ready interchangeability of individual units in the preferred forms, are decided advantages in the art.

Further features and objects of the invention -will be apparent from the following detailed description, and the accompanying drawings in ii which:

Fig. 1 is a view in perspective of a preferred form of individual, pre-shaped floor block pursuant to my invention.

- Fig. 2. is a vertical section, taken on line 2-'-2 of Fig. 3, illustrating individual floor blocks of Fig. 1 assembled in a preferred embodiment of floor construction.

Fig. 3 is a top floor plan of the embodiment illustrated in Fig. 2. 1

Fig. 4 is an enlarged fragmentary detail view in vertical section taken on line 4-4 of Fig. 3.

Fig. 5 is a vertical section taken on line 5-5 of Fig. 3, and showing shoring temporarily supporting the partially completed floor construction.

Fig. 6 is an enlarged fragmentary detail view in vertical section taken on line 6-5 of Fig. 3.

Fig. 7 is an enlarged detail view in perspective of an insert element shown in Fig. 6.

Fig. 8 is a view corresponding to Fig. 6 but 11- lustrating another embodiment.

Fig. 9 is a fragmentary view in perspective i1- iustrating another type of pre-shaped block.

Fig. 10 is an enlarged fragmentary view, in vertical section, of an embodiment of the floor construction utilizing the floor block of Fig. 9.

Fig. 11 is a perspective fragmentary view showing a method of forming reinforcement-spacermeans integral with the individual floor block.

Fig. 12 is a view in perspective of another type of individual floor block, pre-shaped to provide cross bracing in the assembled floor construction.

Fig. 13 represents a vertical section, longitudiml with respect to the arrangement of Fig. 3, 4 through a floor construction embodying the floor blocks of Fig. 12.

Referring to the drawings, and particularly to Figs. 1 through 5, at i0 is indicated an individual building block, pre-shaped to include preferably a slab portion H; having a suitable floor surface Na, a peripheral side surface II b, and an under surface He; and, further, to include sets l2 and iii of parallel spaced flanges I21; and lib, and 13a. and l3b, respectively, the flange sets I! and I3 depending in mutually parallel, spacial relation from the undersnrface lie of the slab portion II, and extending" between two opposite faces of the peripheral side surface llb. The block III is desirably of a rectangular configuration with the flange sets I! and I3 extending between the two longer sides thereof, and spaced apart inwardly from the two shorter sides or ends. To provide for proper beam formation upon assembly of a plurality of blocks in a building construction, as hereinafter described, the related flanges Ila. and I2b, and Na and l3b of each set I! and I3, respectively, of flanges preferably define between each other an open slot having a mean width substantially commensurate with, or less than the mean thickness of an individual flange, and a mean depth substantially equal to the outward extension of the flanges, the width of the slot being small compared to the distance between the sets of flanges l2 and I 3, respectively.

Advantageously the peripheral side surface I I b defines a groove M which completely encircles the slab I laterally, to allow for joinder of assembled blocks.

The blocks ID are preferably of cast concrete, the flanges I241, [21) and 13a, l3b being formed integral with the slab portion il. Reinforcing steel mesh l5, see Fig. 5, may be included within the slab i I during the casting operation; its two ends l5a,, l5a being preferably disposed proximate the floor surface Ha, and the central portion lib curving downward to approximate a catenary.

The block l0 thus formed is symmetrical. Consequently, in an assembly of such blocks any one block may be readily interchanged with another without disturbing the general continuity of the construction.

In assembling the floor construction illustrated in Figs. 2, 3 and 5, the individual building blocks ID are positioned end-to-end and side-by-side on the shoring l6, see Figs. 2 and 5, the flanges l2a. and l2b and Ba and I3b of the flange sets l2 and I3, respectively, aligning end-to-end with like flanges of adjacent blocks to compositely form channeled beams, Figs. 2 and 5, extending completely across the resulting construction.

Advantageously, the blocks are disposed in staggered relation respective to one another, as clearly shown in Fig. 3, the flanges i211. and MD, of one block, according to the arbitrary designation here used, aligning with the flanges Ba and l3b, respectively, of adjoining blocks. The channel included within a composite beam and defined by the respectively end-to-end aligned flanges is designated I1.

Assembly of the blocks, as above, includes the positioning of inserts l8, shown in detail in Figs. 6 and 7, in spaced relation .to each other between the coordinating grooves ll of adjacent blocks. The grooves, as shown, are preferably of a wide V- formation, the vertex of the V being oflset upwardly from the horizontal axis of the slab II to give the lower V-lip Ha, a greater outward protrudence than the upper V-lip I 4b. Consequently, coordinating grooves of contiguous blocks define a, substantially diamond-shaped space l4--l between slab portions H of the blocks, the space being closed at the bottom by contact of the lower V-lips Ma, and being open lengthwise along its top by reason of the spacial relationship of the upper V-lips I do. The inserts I8 are shaped, see Fig. 7, to conform to the cross-sectional area of the space i4i, and are preferably positioned at locations near the corners of the slabs. Desirably, the upper portion of the insert i8 is reduced in height and flattened, as at l8a, for a purpose hereinafter set forth.

minforcing means, such as the rods l9, are positioned within the channel I! formed compositeiy by the alignment of the spacially related flanges Ila and lib, and Ila and l3b, respectively,

the channels running completely across the floor.

proper.

Reinforcing means are positioned within the channels l1, and co-extensive therewith iength wise, to efl'ect a tying together of the assembled blocks. Such reinforcing means preferably take the form of tie-rods i9, each pre-bent to approximately the curvature of a catenary, and disposed within the channel I! with its vertex I9a directed downwardly, and each of its ends I91), I91), see Fig. 4, extending slightly beyond its respective edge of the floor proper, to receive thereon an angle end-plate 20; the end-plates 20 and therewith the tie-rod l9, being securely held in place by means of the nuts 2| bearing, respectively, in threaded engagement with the ends I911, Nb of the rod l9 against the tapered-washers 22.

Between the body of the rod l9 and the undersurfaces Hc of the slabs H are spacer-inserts 23, being preferably individual blocks of suitable material such as wood, metal, etc., and having a curvature approximating the curvature of the rod l9 to provide a firm conforming abutment therefor. The angle plates 20 fit snugly, as shown in detail in Fig. 4, around the respective end surfaces of the floor proper, and the washers 22 are tapered, respectively, as illustrated, to provide a bearing surface normal to the horizontal and also a bearing surface normal to the axis of threading of the threaded tie-rod end Mb, The nuts 2| may be tightened against the washers 22 as desired to effect suitable tensioning of the tierod l9, the spacerinserts 23 presenting abutment surfaces along the length of the rod under tension.

Desirably, a cementitious material 24, see Fig. 5, is grouted into the channel I! to complete the formation of composite beams. In the embodiment of floor construction just described, the shoring i6 is placed between the sets of aligned flanges, and the material 24 is grouted into the channel I1 from below the floor structure. Any suitable means, such as the furring strip 25, Fig. 5, may be employed to retain the grout 24 in place during the stage of hardening.

Bonding of the blocks proximate the floor surface may be accomplished by grouting a suitable bonding material, such as the cementitious mortar 26, into the space I l-I between the coordinating grooves H of contiguous units and between and around the spaced inserts l8.

Before grouting, however, reinforcing rods 21 .may be laid on top of the surfaces 18a, and may thus be incorporated into the bonded joint between blocks.

Fig. 8 illustrates another form the joinder between contiguous slabs Il may advantageously take. A continuous helix 30, usually of steel, and of a diameter to effect alignment between ad- 'jacent blocks is positioned within the space l|-l. If desired, a reinforcing rod 3| may be disposed within the helix 30. Bonding of the joint may then be accomplished by grouting into the space I 4-4 as heretofore explained relative to Fig. 6.

Fig. 9 illustrates, fragmentarily, a building block similar in general configuration to the block l0, Fig. 1. Fig. 10 illustrates a floor construction assembled from the blocks of Fig. 9 in the same manner as the floor construction of Fig. 2 is assembled from the blocks of Fig. 1. Parts of Figs. 9 and 10 identical with parts of Figs. 1 and 2 are designated correspondingly; a prime has been added, however, to the numerals of the latter group to differentiate the two embodiments.

The block HI, Fig. 9, includes, as an additional feature over the block I0, Fig. 1, means whereby, upon assembly of a number of the blocks in contiguous relationship, a passage of communication is aiforded between the flooring surface Ila of the slab ii and the under-surface lie at a location between relatcd flanges l2a' and i212 (not shown) and i3a and l3b. I

Such means preferably take the form of the semi-funnel-shaped indentations 32 defined in the lateral peripheral surface Lib at respective locations thereof directly above the space between relatedflanges. Thus, when the blocks H) are assembled in contiguous relation with one another, as in Fig. 10, sets of two individual indentations 32 coordinate to form substantially funnel-shaped openings 33 leading from the flooring surface Ila into the channel II of composite beams.

The blocks iii are assembled on shoring 16' to utilize such shoring as a lengthwise closure for the open channels i1 during the hardening of grouting material. Grouting is accomplished, from the flooring surface through the passages 33, the passages themselves being finally filled to floor level with the grouting material.

In the embodiment of floor construction illustrated in Fig. 10, wood block spacer-inserts of comparatively small cross-sectional area are shown as a substitute for the spacer-inserts 23 of Fig. 2.

In certain cases it may be desirable to incorporate space-inserts as integral members of component blocks. In such cases, referring now to Fig. 11, the space between related flanges of any set of flanges of a block i0 may be filled to the required level with a cementitious mortar or the like, as at 35, and the surface of this filler provided with the proper unit-curvature by a form-board 36 having a number of limit-stop marks 31 to correspond with the successive or variant curvatures ensuing in a given embodimerit of floor construction.

A floor construction covering a considerable flooring area is usually provided with cross-bracing between joists or beams for the attainment of solidity and rigidity. Pursuant to the present invention, crcss-bracing may be had by an assembly of units of the type illustrated in Fig. 12.

Such units are preferably identical in configuration to those heretofore illustrated, as at l0, 1, or at if), Fig. 9, except for the addition of preferably centrally located set 40 of spacially related flanges 40a and 40b running lengthwise across the block between the shorter ends thereof, this additional flange-set 40 intersecting the heretofore described primary flange-sets 4| and 42 preferably at right angles, and in such manner as to effect a 4-way communicating space between flanges, see 43, Fig. 12.

Assembly of these units in a floor construction as illustrated in Fig. 13 is accomplished in substantially the same manner as is carried out with respect to Figs. 2 through 3, or Fig. 10. alignment of flange-sets 40 of respective units to form composite cross-beams being had automatically upon alignment of the respective primary flange-sets 4i and 42. Subsequent to the tying in of primary flange-sets by means of the preferably curved, tensioned reinforcing rods 44 which bear against the spacer-inserts to form composite beams or joists, tie-rods 45 are positioned in the composite channels between respectively aligned flanges 40a and 40b, and are secured at the edges of the floor proper by any suitable means. The tie-rods 45 are preferably'straight, and effect a tying together of individual flange-sets 40 into composite cross-beams.

Whereas I have described my invention by reference to specific forms thereof, it will be understood that many changes and modifications may be made without departing from the spirit of the invention.

I claim:

1. In a floor construction, a block pro-shaped to include a plane flooring surface, sets of parallel spacially related flanges depending from the under-side of said flooring surface, each of the said sets of flanges completely crossing the said under surface between two oppositely related edges thereof and being spaced apart from the remaining edges thereof, said related flanges of each set defining between each other an open slot having a mean width substantially commensurate with the mean thickness of an individual flange, and a mean depth substantially equal to the outward extension of the flanges. the width of said slot being small as compared to the distance between any two mutually adjacent sets of related flanges.

2. In a floor construction, a block pro-shaped to include a plane flooring surface, sets of paral lel spacially related flanges depending from the under-side of said flooring surface, each of the said sets of flanges completely crossing the said under surface between two oppositely related edges thereof and being spaced apart from the remaining edges thereof, said related flanges of each set defining between each other an open slot having a mean width substantially cornmensurate with the means thickness of an individual flange, and a mean depth substantially equal to the outward extension of the-flanges, the width of said slot being small as compared to the distance between any two mutually adfor the floor construction, reinforcing means pre shaped to substantially catenary form positioned between related flange members of said composite beams, spacer means between said reinforcing means and the portion of said undersurfaces lying between related flanges. said spacer means corresponding in general contour to the curve of the said reinforcing means, and grouting ma terial surrounding. said reinforcing means and said spacer means.

' 4. In a floor construction, pre-shaped blocks each having sets of parallel, specially related flanges depending from its undersurface and running completely across the same between cpposing sides thereof, said blocks being assembled in end to end and side by side relation to align sets of flanges, and therewith the included component flanges, of mutually adjacent blocks, and to thereby compositely form supporting beams for the floor construction; and reinforcing means positioned between related flange members of said supporting beams to effectively tie together individual units of the floor construction.

5. In a floor construction, pre-shaped blocks each having sets of parallel, spaclally related flanges depending from its undersurface and running completely across the same between opposing sides thereof, said blocks being associated in end to end relation to form rows, and said rows being associated in side by side relation, the individual blocks of any one row being staggered in position with respect to the individual blocks of adjoining rows, and said association of blocks being effective to align sets of flanges, and therewith the included component flanges, of mutually adjacent blocks, and to thereby compositely form supporting beams for the floor construction; and reinforcing means positioned between related flange members of said supporting beams to effectively tie-together individual units of the floor construction.

6. In a floor construction, pre-shaped blocks each having sets of parallel, spacially related flanges depending from its undersurface and running completely across the same between opposing sides thereof, said blocks being associated in end to end relation to form rows, and said rows being associated in side by side relation, the individualblocks of any one row being staggered in position with respect to the individual blocks of adjoining rows, and said association of blocks being effective to align sets of flanges, and therewith the included component flanges, of mutually adjacent blocks, and to thereby compositely form supporting beams for the floor construction, reinforcing means pre-shaped to substantially catenary form positioned between related flange members of said composite beams, spacer means between said reinforcing means and the portion of said undersurfaces lying between related flanges, said spacer means corresponding in gen eral contour to the curve of the said reinforcing means, and grouting material surrounding said reinforcing means and said spacer means.

7. In a floor construction, blocks pre-shaped to include a-floor surface, sets of parallel spacially related flanges depending from the under-side of the said floor surface of each block and extending completely across the same between opposing sides thereof, said blocks being assembled in end .to end and side by side relation to align sets of flanges, and therewith the included component flanges, of mutually adjacent blocks, and to thereby compositely form supporting beams for the floor construction; means for joining individual blocks to one another at locations proximate the floor surface; and reinforcing means positioned between related flange members of said supporting beams to effectively tie together individual units of the floor construction.

8. In a floor construction, blocks pre-shaped to include a floor surface, sets of parallel spacially related flanges depending from the underside of the said floor surface of each block and extending completely across' the same between opposing sides thereof, said blocks being asso-' ciated in end to end relation to form rows, and said rows being associated in side by side relation, the individual blocks of any one row being staggered in position with respect to the individual blocks of adjoining rows, and said association of blocks being effective to align sets of flanges, and therewith the included component flanges, of mutually adjacent blocks, and to thereby compositely form supporting beams for the floor construction; means for joining individual blocks to one another at locations proximate the floor surface; and reinforcing means positioned between related flange members of said supporting beams to effectively tie together individual units of the floor construction.

9. In a floor construction, blocks pre-shaped to include a floor surface, sets of parallel spacially related flanges depending from the underside of th said floor surface of each block and extending completely across the same between opposing sides thereof, said blocks being assembled in end to end and side by side relation to align sets of flanges, and therewith the included component flanges, of mutually adjacent blocks, and to thereby compositely form supporting beams for the floor construction; side surfaces, between the flooring surface and the under-surface of respective blocks, defining grooves; inserts cooperating with coordinating grooves of contiguous blocks; grouting material surrounding said inserts and substantially filling the space between coordinating grooves; and reinforcing means positioned between related flange members of said supporting beams to effectively tie together individual units of the floor construction.-

10. In a floor construction, blocks pre-shaped to include a floor surface, sets of parallel spacially related flanges depending from the underside of the said floor surface of each block and extending completely across the same between opposing sides thereof, said blocks being associated in end to end relation to form rows, and said rows being associated in side by side relation, the individual blocks of any one row being staggered in position with respect to the individual blocks of adjoining rows, and said association of blocks being effective to align sets of flanges, and therewith the included component flanges, of mutually adjacent blocks, and to thereby compositely form supporting beams for the floor construction; side surfaces, between the flooring surface and the undersurface of respective blocks, defining grooves; inserts cooperating with coordinating grooves of contiguous blocks; grouting material surrounding said inserts and substantially fllling the space between coordinating grooves; and reinforcing means positioned between related flange members of said supporting beams to effectively tie together individual units of the floor construction.

11. In a floor construction, pre-shaped blocks each having sets of parallel, spacially related flanges depending from its under surface and running completely across the same between opposing sides thereof, said blocks being associated in end to end relation to form rows, and said rows being associated in side by side relation, the individual blocks of any one row being staggered in position with respect to the individual blocks of adjoining rows, and said association of blocks being effective to align sets of flanges, and therewith the included component flanges, of mutually adjacent blocks, and to thereby compositely form supporting beams for the floor construction, tensioned reinforcing means pre-shaped to substan ing said reinforcing means and said spacer means.

12. In a floor construction, blocks pre-shaped to include a floor surface, sets of parallel spacially related flanges depending from the underside of the said floor surface of each block and extending. completely across the same between opposing sides thereof, said blocks being associated in end to end relation to form rows, and said rows being associated in side by side relation, the individual blocks of any one row being staggered in position with respect to the individual blocks of adjoining rows, and said association of blocks being effective to align sets of flanges, and therewith the included component flanges, of mutually adjacent blocks, and to thereby compositely form supporting beams for the floor construction; side surfaces, between the flooring surface and the undersurface of respective blocks, defining grooves; inserts cooperating withcoordinating grooves of contiguous blocks; grouting material surrounding said inserts and substantially fllling the space between coordinating grooves; tensioned reinforcing means pre-shaped to substantially catenary form positioned between related flange members of said composite beams, spacer means between said reinforcing means and the portion of said undersurfaces lying between related flanges, said spacer means corresponding in general contour to the curve of the said reinforcing means, and grouting material surrounding said reinforcing means and said spacer means.

13. In a building construction, building blocks each comprising a slab body portion the lateral sides of which define grooves, collectively, completely encircling the slab, each groove comprehending a. major portion of the surface of its respective lateral side, and the lower defining-edge of each groove extending outwardly from the block a greater distance than does the upper defining edge, said building blocks being associated end to end and side by side with the lower defining-edges of adjacent grooves contiguous to each other and lying between the planes of the opposite major faces of the slab body portions of the blocks and means effecting joinder between adjacent blocks at locations of coordinating grooves.

14. In a floor construction, a block pre-shaped to include a floor slab, a plurality of parallel, spacially related sets of parallel, spacially related flanges depending from the under-side of said floor slab and extending between two opposite sides thereof and located intermediate the other sides thereof, and a set of parallel, spacially related flanges depending from the under-side of said floor slab and extending between the last named sides thereof and located intermediate the first named sides thereof.

' 15. In a floor construction, a block pre-shape'd to include a floor slab, a plurality of parallel, spacially related sets of parallel, spacially related flanges depending from the under-side of said floor slab and extending between two opposite sides thereof and located intermediate the other sides thereof, and a. set of parallel, spacially related flanges depending from the under-side of said fioor slab and extending between the last named sides thereof and located intermediate the first named sides thereof, the last named set of flanges intersecting the first named sets of flanges at right angles, a four-way channelcrossing resulting at locations of intersection of said flanges.

16. In a. floor construction, an assembly of blocks each pre-shaped to include a floor slab, a plurality of parallel, spacially related sets of parallel, spacially related flanges depending from the under-side of the floor slab and extending between two opposite sides thereof and located intermediate the other sides thereof, a set of parallel, spacially related flanges depending from the under-side of the floor slab and extending between the last named sides thereof and located intermediate the first named sides thereof, a four-way channel-crossing resulting at locations of intersection of said flanges, and means for joining contiguous sides of adjacent floor slabs; said blocks being associated in end to end relation to form rows, and said rows being associated in side by side relation, the individual blocks of any one row being staggered in position with respect to the individual blocks of adjoining rows, and said association of blocks being effective to align sets of flanges, and therewith the included component flanges, of adjacent blocks, and to thereby compositely form supporting beams and cross-bracing beams for the floor construction; reinforcing means positioned between related flange members of said supporting beams to effectively tie together individual units of the floor construction.

' 17. In a floor construction, an assembly of blocks each pre-shaped to include a floor slab, a plurality of parallel, spacially related sets of parallel, spacially related flanges depending from the under-side of the floor slab and extending between two opposite sides thereof and located intermediate the other sides thereof, a set of parallel, spacially related flanges depending from the under-side of the floor slab and extending between the last named sides thereof and located intermediate the first named sides thereof, a four-way channel-crossing resulting at locations of intersection of said flanges, and means for joining contiguous sides of adjacent floor slabs; said blocks being associated in end to end relation to form rows, and said rows being associated in side by side relation, the individual blocks of any one row being staggered in position with respect to the individual blocks of adjoining rows, and said association of blocks being effective to align sets of flanges, and therewith the included component flanges, of adjacent blocks, and to thereby compositely form supporting beams and cross-bracing beams for the floor construction; tensioned reinforcing tie-rods shaped to substantially catenary form positioned between related flange members of said supporting beams, spacer abutment means between said tie-rods and the portion of the under-side of said floor slabs lying between related flanges, reinforcing tie-rods between related flange members of said cross-bracing beams and positioned below said curve tie-rods, and grouting material surrounding the reinforcing tie-rods and the said spacer means.

HERBERT ALFRED FABER. 

